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Abstract:

A projector type vehicle light can have a decreased total weight and
prevent the insufficiency in strength of a rotational shaft of a base
member. The projector type vehicle light can include a light source, a
reflector, a shade, and a projection lens. The vehicle light can further
include a shade rotational shaft extending in the left-to-right
direction, a base member configured so that the shade can rotate around
the shade rotational shaft, a solenoid for making the shade rotate
between a low-beam position and a high-beam position, and a crank shaft
configured to connect the solenoid with the shade for driving the shade.
The solenoid can be supported by the base member so that the plunger of
the solenoid can move in the left-to-right direction. The lens holder can
be made of a first material, such as a resin material, and the base
member can be made from a second material, such as metal material.

Claims:

1. A projector type vehicle light comprising:a light source;a reflector
spaced from the light source in a first direction and configured to
reflect light from the light source;a shade configured to shield a first
portion of the light reflected by the reflector and including a shade
rotational shaft extending in a second direction that is substantially
perpendicular to the first direction;a projection lens configured to
project a second portion of the light reflected by the reflector, wherein
the second portion of the light reflected by the reflector is different
from the first portion of the light reflected by the reflector;a base
member supporting the shade so that the shade can rotate around the shade
rotational shaft;a solenoid supported by the base member and having a
plunger movable in the second direction and connected to the shade to
rotate the shade between a low-beam position and a high-beam position;a
crank shaft movably connecting the solenoid to the shade; anda lens
holder receiving the projection lens, the lens holder being formed of a
member separate from the base member, wherein the lens holder is made of
a resin material and the base member is made of a metal material.

2. The projector type vehicle light according to claim 1, wherein the
light source, the reflector, the base member, the lens holder, the shade
and the projection lens cooperate with one another to define a lamp unit,
and the projector type vehicle light further comprises a rotational shaft
extending in a third direction and formed integrally with the base member
so that the lamp unit can rotate around the rotational shaft, wherein the
third direction is substantially perpendicular to each of the first
direction and the second direction.

3. The projector type vehicle light according to claim 2, wherein the
third direction of the projector type vehicle light is substantially
collinear to a vertical line on which the center of gravity of the lamp
unit is positioned.

4. The projector type vehicle light according to claim 1, wherein the
projector type vehicle light is a vehicle headlight.

5. A method for manufacturing the projector type vehicle light according
to claim 1, the method comprising:providing a molding device including:a
first mold and a second mold movable in the first direction:a first slide
mold and a third slide mold movable in a third direction substantially
perpendicular to the first direction and the second direction and
moveable upward in the third direction with respect to the first mold and
the second mold, wherein the first slide mold includes a shaft cavity and
the third slide mold is configured different from the first slide mold:
anda second slide mold and a fourth slide mold movable in the third
direction and downward with respect to the first mold and the second
mold, wherein the second slide mold includes a shaft cavity and the
fourth slide mold is configured different from the second slide
mold;forming the base member with an integral rotational shaft extending
in the third direction using the first slide mold and the second slide
mold and including:disposing the first slide mold above the first mold
and the second mold; anddisposing the second slide mold below the first
mold and the second mold; andforming the base member without the integral
rotational shaft extending in the third direction using the third slide
mold and the fourth slide mold and including:disposing the third slide
mold above the first mold and the second mold; anddisposing the fourth
slide mold below the first mold and the second mold.

6. The manufacturing method according to claim 5, wherein, when the center
of gravity of the lamp unit is disposed on a front half part of the base
member, the first slide mold and the second slide mold have the
respective cavities in respective front half parts thereof, and when the
center of gravity of the lamp unit is disposed on the rear half part of
the base member, the first slide mold and the second slide mold have the
respective cavities in respective rear half parts thereof.

7. A vehicle light comprising:a light source;a reflector spaced from the
light source in a first direction and configured to reflect light from
the light source;a shade configured to shield a first portion of the
light reflected by the reflector and including a shade rotational axis
extending in a second direction that is substantially perpendicular to
the first direction;a projection lens configured to project a second
portion of the light reflected by the reflector, wherein the second
portion of the light reflected by the reflector is different from the
first portion of the light reflected by the reflector;a base member
supporting the shade so that the shade can rotate around the shade
rotational axis;a solenoid supported by the base member and having a
plunger connected to the shade to rotate the shade between a low-beam
position and a high-beam position;a crank shaft movably connecting the
solenoid to the shade; anda lens holder receiving the projection lens and
connected to the base member, the lens holder being formed of a member
separate from the base member, wherein the lens holder is made of a first
material and the base member is made of a second material different from
the first material.

8. The vehicle light according to claim 7, wherein the first material is a
resin material and the second material is a metal material.

9. The vehicle light according to claim 7, wherein the plunger moves along
a linear path that is substantially parallel to the second direction.

10. The vehicle light according to claim 9, wherein the shade rotational
axis is spaced from the plunger in each of the first direction and a
third direction, wherein the third direction is substantially
perpendicular to each of the first direction and the second direction.

11. The vehicle light according to claim 10, wherein the crank includes:an
upper support part rotatably mounted on the base member;a lower support
part rotatably mounted on the base member, wherein the upper support part
and the lower support part lie along a center axis that extends
substantially parallel to the third direction;an input part movably
connected to the plunger and spaced from the center axis; andan output
part movably connected to the shade and spaced from the center axis.

12. The vehicle light according to claim 7, wherein the base member
further includes a shaft extending in a third direction that is
substantially perpendicular to each of the first direction and the second
direction, and the shaft is integrally formed as a single homogenous
component with the base member from a metal material.

13. A method for manufacturing a vehicle light comprising:providing a
first mold, a second mold, a first slide mold including a first shaft
cavity at a first relative position on the first slide mold, a second
slide mold including a second shaft cavity at a second relative position
on the second slide mold, a third slide mold, and a fourth slide
mold;selecting one of the first slide mold and the third slide
mold;selecting one of the second slide mold and the fourth slide
mold;molding a base member with the first mold, the second mold, the
selected one of the first slide mold and the third slide mold, and the
selected one of the second slide mold and the fourth slide mold;
andconnecting the base member to each of:a light source;a reflector
spaced from the light source in a first direction and configured to
reflect light from the light source;a shade configured to shield a first
portion of the light reflected by the reflector and including a shade
rotational shaft extending in a second direction that is substantially
perpendicular to the first direction;a projection lens configured to
project a second portion of the light reflected by the reflector, wherein
the second portion of the light reflected by the reflector is different
from the first portion of the light reflected by the reflector;a solenoid
including a plunger movable in the second direction and connected to the
shade to rotate the shade between a low-beam position and a high-beam
position;a crank shaft movably connecting the solenoid to the shade; anda
lens holder connected to the projection lens.

14. The method for manufacturing a vehicle light according to claim 13,
wherein the molding the base member further includes:moving at least one
the first mold and the second mold substantially parallel to the first
direction;moving the selected one of the first slide mold and the third
slide mold along a third direction that is substantially perpendicular to
each of the first direction and the second direction; andmoving the
selected one of the second slide mold and the fourth slide mold along the
second direction.

15. The method for manufacturing a vehicle light according to claim 13,
wherein molding the base member further includes:aligning the first mold
to oppose the second mold;closing the first mold and second mold by
moving the first mold toward the second mold along the first
direction;aligning the selected one of the first slide mold and the third
slide mold along a first portion of each of the first mold and second
mold;aligning the selected one of the second slide mold and the fourth
slide mold along a second portion of each of the first mold and second
mold, wherein the second portion is spaced from and opposite to the first
portion; andclosing the selected one of the first slide mold and the
third slide mold and the selected one of the second slide mold and the
fourth slide by moving the selected one of the first slide mold and the
third slide mold toward the selected one of the second slide mold and the
fourth slide mold in a third direction, wherein the third direction is
substantially perpendicular to each of the first direction and the second
direction.

16. The method for manufacturing a vehicle light according to claim 13,
wherein molding the base member further includes molding the base member
from a metal material.

17. The method for manufacturing a vehicle light according to claim 13,
wherein providing further includes providing a fifth slide mold including
a fifth shaft cavity at a fifth relative position on the fifth slide mold
and a sixth slide mold including a sixth shaft cavity at a sixth relative
position on the sixth slide mold;wherein the fifth relative position is
different from the first relative position and the sixth relative
position is different from the second relative position.

18. The method for manufacturing a vehicle light according to claim 17,
wherein:selecting one of the first slide mold and the third slide mold
includes selecting one of the first slide mold, the third slide mold, and
the fifth slide mold; andselecting one of the second slide mold and the
fourth slide mold includes selecting one of the second slide mold, the
fourth slide mold, and the sixth slide mold.

19. The method for manufacturing a vehicle light according to claim 18,
wherein molding the base member further includes:aligning the first mold
to oppose the second mold;closing the first mold and second mold by
moving the first mold toward the second mold along the first
direction;aligning the selected one of the first slide mold, the third
slide mold, and the fifth slide mold along a first portion of each of the
first mold and second mold;aligning the selected one of the second slide
mold, the fourth slide mold, and the sixth slide mold along a second
portion of each of the first mold and second mold, wherein the second
portion is spaced from and opposite to the first portion; andclosing the
selected one of the first slide mold, the third slide mold, and the fifth
slide mold and the selected one of the second slide mold, the fourth
slide mold, and the sixth slide mold by moving the selected one of the
first slide mold, the third slide mold, and the fifth slide mold toward
the selected one of the second slide mold, the fourth slide mold, and the
sixth slide mold in a third direction, wherein the third direction is
substantially perpendicular to each of the first direction and the second
direction.

Description:

[0001]This application claims the priority benefit under 35 U.S.C. §
119 of Japanese Patent Application No. 2008-127383 filed on May 14, 2008,
which is hereby incorporated in its entirety by reference.

BACKGROUND

[0002]1. Technical Field

[0003]The presently disclosed subject matter relates to a projector type
vehicle light including a shade that can be rotated between a low-beam
position and a high-beam position by a solenoid. In particular, the
presently disclosed subject matter relates to a projector type vehicle
headlight that can have a decreased total weight and prevent the strength
insufficiency of a rotational shaft when the lamp unit is allowed to be
rotated around the rotational shaft extending in a vertical direction of
the projector type vehicle headlight.

[0004]2. Description of the Related Art

[0005]Conventionally, various projector type vehicle headlights are known
that include a light source, a reflector configured to reflect light from
the light source, a shade configured to shield part of the light received
from the reflector, and a projection lens configured to project light
that is not shielded by the shade. Examples of this type of vehicle
headlights include those shown in FIGS. 1 and 2 (corresponding to FIGS. 1
and 4 of Japanese Patent Application Laid-Open No. 2007-213938).

[0006]In the description of the present application, the directions for
describing a light or headlight (front and rear, left and right, and up
and down directions) are defined based on the state where the light is
installed in a normal vehicle unless otherwise specifically defined.

[0007]The projector type vehicle headlight as shown in FIGS. 1 and 2
includes, in addition to the above basic components, a shade rotational
shaft extending in a horizontal direction (left-to-right direction) of
the headlight, a base member configured to support the shade around the
shade rotational shaft so that the shade can rotate freely, a solenoid
configured to rotate the shade between a low-beam position and a
high-beam position, and a crank shaft for connecting the solenoid with
the shade for driving and rotating of the shade.

[0008]In this structure, when the solenoid is turned off, the shade is
disposed at the low-beam position to shield part of light from the
reflector, thereby forming a low-beam light distribution pattern.

[0009]When the solenoid is turned on, the plunger of the solenoid is
retracted to rotate the crank shaft connected thereto. Then, the rotated
crank shaft can move the shade.

[0010]As a result, the shade is allowed to be disposed at the high-beam
position to form a high-beam light distribution pattern.

[0011]When the solenoid is disposed so that the moving direction of the
plunger can be aligned with the front-to-rear direction, the size of the
vehicle headlight in the front-to-rear direction can be relatively large.
However, in this structure, the solenoid can be disposed so that the
moving direction of the plunger can be aligned with the horizontal
direction (left-to-right or side to side direction) of the projector type
vehicle headlight, and therefore, the size of the vehicle headlight in
the front-to-rear direction can be relatively smaller than when the
plunger moving direction is aligned in the front to rear direction.

[0012]It should be noted that there is no disclosure about what supports
the solenoid and what holds the projection lens in the vehicle headlight
of FIGS. 1 and 2.

[0013]On the other hand, in the projector type vehicle headlight in FIGS.
3 and 4 (corresponding to FIGS. 1 and 3 of Japanese Patent Application
Laid-Open No. 2008-27768), the solenoid is supported by a holder which
also holds the projection lens.

[0014]It should be noted that there is no disclosure about what material
the holder for supporting the solenoid and holding the projection lens is
made of.

[0015]When the holder of the projector type vehicle headlight in FIGS. 3
and 4 is made of a metal material, the entire weight of the headlight is
increased.

[0016]When the holder of the projector type vehicle headlight in FIGS. 3
and 4 is made of a resin material, the headlight can lighten as a whole.

[0017]However, when the holder includes a rotational shaft extending
vertically in the headlight and a lamp unit containing the light source,
reflector, holder, shade, projection lens and the like connected to one
another is allowed to rotate around the rotational shaft, the strength of
the rotational shaft may be decreased.

SUMMARY

[0018]The presently disclosed subject matter was devised in view of these
and other characteristics, features, and problems and in association with
the conventional art. According to an aspect of the presently disclosed
subject matter, a projector type vehicle light or headlight can have a
decreased total weight and prevent the strength insufficiency of a
rotational shaft when a lamp unit can be allowed to be rotated around the
rotational shaft extending in a vertical direction of the projector type
vehicle headlight, the lamp unit containing a light source, reflector,
base member, lens holder, shade, projection lens and the like connected
to one another.

[0019]According to another aspect of the presently disclosed subject
matter, a projector type vehicle light can include: a light source; a
reflector configured to reflect light from the light source; a shade
configured to shield part of light received from the reflector, having a
shade rotational shaft extending in a left-to-right direction of the
projector type vehicle light; a projection lens configured to project
light not shielded by the shade; a base member configured to support the
shade so that the shade can rotate around the shade rotational shaft; a
solenoid having a plunger for making the shade rotate between a low-beam
position and a high-beam position, the solenoid being supported by the
base member so that a moving direction of the plunger can be aligned with
the left-to-right direction of the projector type vehicle light; and a
crank shaft configured to connect the solenoid with the shade for driving
the shade. The vehicle light can further include a lens holder configured
to hold the projection lens, the lens holder being formed of a member
separate from the base member, the lens holder being made of a resin
material and the base member being made of a metal material.

[0020]According to another aspect of the presently disclosed subject
matter, the projector type vehicle light of the immediately
above-described aspect can be configured such that the light source, the
reflector, the base member, the lens holder, the shade and the projection
lens are connected to one another to constitute a lamp unit. The
projector type vehicle light can further include a rotational shaft
extending in a vertical direction (up-to-down direction) of the projector
type light and formed integrally with the base member so that the lamp
unit can rotate around the rotational shaft.

[0021]According to another aspect of the presently disclosed subject
matter, the projector type vehicle light of the immediately
above-described aspect can be configured such that the rotational shaft
extending in the vertical direction of the projector type vehicle light
can be disposed on or near a vertical line on which the center of gravity
of the lamp unit is positioned.

[0022]According to yet another aspect of the presently disclosed subject
matter, a method for manufacturing the projector type vehicle light of
any of the above-described aspects can include: preparing a molding
device including a first mold and a second mold relatively moving in the
front-to-rear direction of the projector type vehicle light, a first
slide mold or a third slide mold disposed above, and moving upward with
respect to, the first mold and the second mold, and a second slide mold
or a fourth slide mold disposed below, and moving downward with respect
to, the first mold and the second mold, the molds being used for molding
the base member; when the rotational shaft extending in the vertical
direction of the projector type vehicle light is molded integrally with
the base member, using the first slide mold having a cavity for the
rotational shaft and the second slide mold having a cavity for the
rotational shaft to mold the base member, or when the rotational shaft
extending in the vertical direction of the projector type vehicle light
is not integrally molded with the base member, using the third slide mold
having no cavity for the rotational shaft and the fourth slide mold
having no cavity for the rotational shaft to mold the base member.

[0023]According to still another aspect of the presently disclosed subject
matter, the manufacturing method of the immediately above-described
aspect can be configured such that, when the center of gravity of the
lamp unit is disposed on the front half part of the base member, the
first slide mold and the second slide mold can have the respective
cavities for the rotational shaft in respective front half parts thereof,
and when the center of gravity of the lamp unit is disposed on the rear
half part of the base member, the first slide mold and the second slide
mold can have the respective cavities for the rotational shaft in
respective rear half parts thereof.

[0024]The projector type vehicle light of the presently disclosed subject
matter can include a shade that can be disposed at the low-beam position
when the solenoid is turned off so that the shade can shield part of
light from the reflector to form a low-beam light distribution pattern.
On the other hand, as the solenoid is turned on and the plunger thereof
is retracted, the crank shaft connected to the plunger can be allowed to
be rotated.

[0025]Then, the crank shaft abutting against the shade can move the shade
rotationally to allow the shade to be disposed at the high-beam position.
This configuration can provide a high-beam light distribution pattern.

[0026]The solenoid can be supported by the base member such that the
moving direction of the plunger of the solenoid can be aligned with the
left-to-right direction of the projector type vehicle light. Accordingly,
when compared with the case where the solenoid can be supported by the
base member so that the moving direction of the plunger of the solenoid
can be aligned with the front-to-rear direction, the size in the
front-to-rear direction of the projector type vehicle light can be
miniaturized.

[0027]In addition, the lens holder for holding the projection lens can be
formed of a member separate from the base member. In this instance, the
lens holder can be made of a resin material while the base member can be
made of a metal material. When compared with the case where the lens
holder is made of a metal material, the projector type vehicle light can
lighten as a whole.

[0028]In one embodiment, the light source, the reflector, the base member,
the lens holder, the shade, and the projection lens are connected to one
another to constitute a lamp unit. The lamp unit can be allowed to be
rotated around the rotational shaft extending in the vertical direction
of the projector type vehicle light. Then, the rotational shaft and the
base member are integrally formed with each other.

[0029]Namely, the rotational shaft can be made of a metal material
integrally with the base member. Accordingly, when compared with the case
where the rotational shaft is made of a resin material so that the shaft
has an insufficient strength, the presently disclosed subject matter can
provide a sufficient strength to the rotational shaft.

[0030]The projector type vehicle light of the presently disclosed subject
matter can be configured such that the rotational shaft can be disposed
on or near the vertical line on which the center of gravity of the lamp
unit is positioned. Accordingly, when compared to the case where the
rotational shaft is disposed away from the vertical line containing the
center of gravity, the moment applied to the rotational shaft can be
reduced. This can further reduce the rotational resistance of the lamp
unit with the rotational shaft as its center.

[0031]The manufacturing method of the projector type vehicle light of the
presently disclosed subject matter can be configured such that, when the
rotational shaft extending in the vertical direction of the projector
type vehicle light is molded integrally with the base member, the first
slide mold having a cavity for the rotational shaft and the second slide
mold having a cavity for the rotational shaft are used. Alternatively,
when the rotational shaft is not integrally molded with the base member,
the third slide mold having no cavity for the rotational shaft and the
fourth slide mold having no cavity for the rotational shaft are used.

[0032]Accordingly, when different type of base member is molded, there may
be no need to replace the entire molding device, but only the first slide
mold and the second slide mold are replaced with the third slide mold and
the fourth slide mold. This can facilitate the selective manufacturing of
a base member with or without the rotational shaft.

[0033]The manufacturing method of the projector type vehicle light of the
presently disclosed subject matter can be configured such that, when the
center of gravity of the lamp unit is disposed on the front half part of
the base member, the first slide mold and the second slide mold can have
the cavity for the rotational shaft in respective front half parts
thereof. Alternatively, when the center of gravity of the lamp unit is
disposed on the rear half part of the base member, the first slide mold
and the second slide mold can have the cavity for the rotational shaft in
respective rear half parts thereof.

[0034]Accordingly, when different type of base member is molded, there may
be no need to replace the entire molding device, but only the first slide
mold and the second slide mold are replaced with another set of the first
slide mold and the second slide mold having the cavity in respective rear
half parts thereof. This can facilitate the selective manufacturing of a
base member with the rotational shaft disposed in the rear or front part.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035]These and other characteristics, features, and advantages of the
presently disclosed subject matter will become clear from the following
description with reference to the accompanying drawings, wherein:

[0039]FIG. 4 is a perspective view illustrating a shade and surrounding
parts of the conventional projector type vehicle headlight (corresponding
to FIG. 3 of Japanese Patent Application Laid-Open No. 2008-27768);

[0040]FIG. 5 is a schematic cross-sectional view illustrating a first
exemplary embodiment of a projector type vehicle headlight made in
accordance with principles of the presently disclosed subject matter when
viewed from its right side;

[0041]FIGS. 6A, 6B, and 6C are schematic diagrams illustrating parts of
the shade of FIG. 5;

[0042]FIGS. 7A and 7B are schematic diagrams illustrating parts of the
base member of FIG. 5;

[0043]FIGS. 8A, 8B, and 8C are schematic diagrams of the solenoid of FIG.
5;

[0044]FIGS. 9A, 9B, and 9C are schematic diagrams of the crank shaft of
FIG. 5 for connecting the plunger of the solenoid with the shade for
driving the shade;

[0046]FIG. 11 is a schematic view illustrating the assembly of the base
member, the solenoid, and the crank shaft of FIG. 5;

[0047]FIGS. 12A, 12B, 12C and 12D are schematic diagrams illustrating a
linkage mechanism for rotating and moving the shade between the low-beam
position and the high-beam position for the light of FIG. 5;

[0048]FIG. 13 is a schematic view illustrating a molding device for
molding the base member of the projector type vehicle headlight according
to the first exemplary embodiment;

[0049]FIG. 14 is a schematic cross-sectional view illustrating a second
exemplary embodiment of a projector type vehicle headlight made in
accordance with principles of the presently disclosed subject matter when
viewed from its right side;

[0050]FIG. 15 is a schematic view illustrating a molding device for
molding the base member of the projector type vehicle headlight according
to the second exemplary embodiment; and

[0051]FIG. 16 is a schematic view illustrating a molding device for
molding the base member of the projector type vehicle headlight according
to a third exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0052]A description will now be made below to projector type vehicle
lights of the presently disclosed subject matter with reference to the
accompanying drawings in accordance with exemplary embodiments. FIG. 5 is
a schematic cross-sectional view illustrating a projector type vehicle
headlight 100 of a first exemplary embodiment cut along the front-to-rear
direction.

[0053]As shown in FIG. 5, the projector type vehicle headlight 100 of the
first exemplary embodiment can include a light source 1 such as a bulb, a
reflector 2 configured to reflect light from the light source 1, a shade
3 configured to shield part of the light received from the reflector 2,
and a projection lens 4 configured to project light not shielded by the
shade 3.

[0054]The reflector 2 can be a molded article made of a resin material and
can include a reflecting surface with deposited aluminum. The presently
disclosed subject matter is not limited to this particular embodiment,
and the reflector 2 can be made of a metal material such as a die cast
aluminum part, etc.

[0055]The shade 3 can be a die cast aluminum part. The presently disclosed
subject matter is not limited to this particular embodiment, and the
shade 3 can be made of any appropriate material such as a sheet metal,
ceramic, coated plastic, etc.

[0056]The projector lens 4 can be made of a transparent resin material in
a predetermined shape.

[0057]The reflector 2 can be connected to the projector lens 4 via the
base member 12 and the lens holder 15.

[0058]The base member 12 can be made of a metal material such as a die
cast aluminum part. The lens holder 15 for holding the projection lens 4
can be made of a resin material by a molding method. Namely, in the
projector type vehicle headlight 100 of the first exemplary embodiment,
as shown in FIG. 5, the lens holder 15 and the base member 12 are formed
of respective separate members.

[0059]The shade 3 can be supported by the base member 12 so that the shade
3 can rotate freely around the shade rotational shaft 11 extending in the
right-to-left direction of the projector type vehicle headlight 100. In
this illustrate example, the shade 3 and the shade rotational shaft 11
can be formed of respective separate members. However, the presently
disclosed subject matter is not limited to a particular embodiment.
Instead, the shade 3 and the shade rotational shaft 11 can be formed as a
single part member.

[0060]In the projector type vehicle headlight 100 of the first exemplary
embodiment, as shown in FIGS. 5 and 11, the solenoid 13 can be configured
to rotate and move the shade 3 between the low-beam position and the
high-beam position. This solenoid 13 can be installed in the seat portion
12d of the base member 12.

[0061]As shown in FIG. 5, in the projector type vehicle headlight 100 of
the first exemplary embodiment, the light source 1, the reflector 2, the
base member 12, the shade rotational shaft 11, the shade 3, the solenoid
13, the lens holder 15, and the projector lens 4 are connected to one
another to constitute a lamp unit 50. The lamp unit 50 can be supported a
bracket 52 so that it can rotate around rotational shafts 12j and 12k
extending in a vertical direction of the projection type vehicle
headlight 100 (in the up-to-down direction of FIG. 5). An actuator 51 can
be provided to rotate the lamp unit 50 with respect to the bracket 52.
The lamp unit 50, the bracket 52, the actuator 51 can constitute an
assembly. The vehicle headlight 100 can further include a housing 101 and
a cover lens 102 together defining a lighting chamber 103. This assembly
can be disposed within the lighting chamber 103. In this state, the
bracket 52 and the housing 101 may be connected to each other via an
aiming screw 104 and a ball joint 105.

[0062]FIGS. 6A, 6B, and 6C show the shade 3 of FIG. 6. Specifically, FIG.
6A is a rear side view of the shade 3 and the like (as seen from the rear
side of the projector type vehicle headlight 100 in which the shade 3 is
installed). FIG. 6B is a right side view of the shade 3 (as seen from the
left side of the shade 3 of FIG. 6A). FIG. 6c is a cross-sectional view
taken along a line A-A in FIG. 6A. FIGS. 7A and 7B are diagrams
illustrating the base member 12 of FIG. 5. Specifically, FIG. 7A is a
rear side view of the base member 12 (as seen from the rear side of the
projector type vehicle headlight 100 in which the base member 12 is
installed). FIG. 7B is a cross-sectional view taken along a line B-B in
FIG. 7A.

[0063]FIGS. 8A, 8B, and 8C are schematic diagrams of the solenoid 13 of
FIG. 5. Specifically, FIG. 8A is a right side view of the solenoid 13 (as
seen from the right side of the projector type vehicle headlight 100 in
which the solenoid 13 is installed). FIG. 8B is a rear side view of the
solenoid 13 (as seen from the rear side of the projector type vehicle
headlight 100 in which the solenoid 13 is installed). FIG. 8c is a bottom
view of the solenoid 13 (as seen from the bottom side of the projector
type vehicle headlight 100 in which the solenoid 13 is installed).

[0064]FIGS. 9A, 9B, and 9C are schematic diagrams of the crank shaft 14 of
FIG. 5 for connecting the plunger 13a of the solenoid 13 with the shade
for driving. Specifically, FIG. 9A is a plan view of the crank shaft 14
(as seen from the upper side of the projector type vehicle headlight 100
in which the crank shaft 14 is installed). FIG. 9B is a right side view
of the crank shaft 14 (as seen from the right side of the projector type
vehicle headlight 100 in which the crank shaft 14 is installed). FIG. 9c
is a rear side view of the crank shaft 14 (as seen from the bottom side
of the projector type vehicle headlight 100 in which the crank shaft 14
is installed). FIGS. 10A, 10B, and 10C are schematic diagrams
illustrating parts of the lens holder 15 of FIG. 5. Specifically, FIG.
10A is a plan view of the lens holder 15 (as seen from the upper side of
the projector type vehicle headlight 100 in which the lens holder 15 is
installed). FIG. 10B is a rear side view of the lens holder 15 (as seen
from the rear side of the projector type vehicle headlight 100 in which
the lens holder 15 is installed). FIG. 10C is a bottom side view of the
lens holder 15 (as seen from the bottom side of the projector type
vehicle headlight 100 in which the lens holder 15 is installed).

[0065]In the projector type vehicle headlight 100 of the first exemplary
embodiment as shown in FIGS. 5, 6A, 6B, and 6C, the upper edge 3a of the
shade 3 contributes to form the cutoff line for forming the low-beam
light distribution pattern. Furthermore, the shade rotational shaft 11
can be inserted into an insertion hole 3b of the shade 3. A coil spring
16 can be provided and can include one end which can be engaged with a
coil engagement portion 3c of the shade 3 for urging the shade 3 toward
the low-beam position.

[0066]The output part 14d of the crank shaft 14 (see FIGS. 9A, 9B, and 9C)
can be allowed to abut against the abutment portion 3d of the shade 3
(see FIGS. 6A, 6B, and 6C) to rotate the shade 3 from the low-beam
position to the high-beam position.

[0067]The base member 12 can include an opening 12a substantially at its
center area (see FIG. 7A). Accordingly, the light reflected from the
reflector 2 is allowed to pass through the opening 12a of the base member
12. The right end portion of the shade rotational shaft 11 can be
supported by a groove 12b of the base member 12 to be freely rotated
while the left end portion of the shade rotational shaft 11 can be
supported by a groove 12c of the base member 12. Specifically, for
example, the right end portion and left end portion of the shade
rotational shaft 11 are inserted into the respective grooves 12b and 12c
of the base member 12, and cover members (not shown) cover the respective
grooves 12b and 12c of the base member 12 to complete the supporting
structure.

[0068]On the other hand, as shown in FIGS. 9A, 9B, and 9C, the crank shaft
14 can include the input part 14c, upper and lower supported parts 14a
and 14b, and the output part 14d. The upper and lower supported parts 14a
and 14b are rotatably supported by respective grooves 12e and 14f of the
base member 12 (see FIG. 11). Specifically, for example, the upper and
lower supported parts 14a and 14b of the crank shaft 14 are inserted into
the respective grooves 12e and 12f of the base member 12, and cover
members (not shown) cover the respective grooves 12e and 12f of the base
member 12 to complete the supporting structure.

[0069]Further the other end of the coil spring 16 can be engaged with a
coil engagement portion 12g of the base member 12 for urging the shade 3
toward the low-beam position (see FIGS. 6A, 7A, and 11).

[0070]Furthermore, as shown in FIGS. 9A, 9B, 9C, 11, 12A, 12B, 12C and
12D, the output part 14c of the crank shaft 14 can be fit into the groove
13a1 of the plunger 13a of the solenoid 13.

[0071]FIGS. 12A, 12B, 12C, and 12D illustrate an exemplary linkage
mechanism for rotating and moving the shade 3 between the low-beam
position and the high-beam position. Specifically, FIG. 12A is a right
side view of the crank shaft 14 and the shade 3 which is disposed at the
low-beam position (where the shade 3 shields part of the light path).
FIG. 12B is a plan view of the solenoid 13 and the crank shaft 14 in the
state where the shade 3 is disposed at the low-beam position. FIG. 12c is
a right side view of the crank shaft 14 and the shade 3 which is disposed
at the high-beam position (where the shade 3 is retracted from the light
path). FIG. 12D is a plan view of the solenoid 13 and the crank shaft 14
in the state where the shade 3 is disposed at the high-beam position.

[0072]In the projector type vehicle headlight 100 of the first exemplary
embodiment, the solenoid 13 is turned off (see FIG. 12B) when the
low-beam light distribution pattern is to be formed. In this case, the
plunger 13a of the solenoid 13 is not retracted. Then, the shade 3 can be
urged by the coil spring 16 (see FIG. 6A) toward the low-beam position
(at the position as shown in FIG. 12A). As a result, as shown in FIGS. 5
and 12A, the upper edge 3a of the shade 3 can be disposed to shield the
light path of light reflected from the reflector 2. Therefore, the upper
edge 3a of the shade 3 can form the cut-off line of the low-beam light
distribution pattern.

[0073]When the high-beam light distribution pattern is to be formed, the
solenoid 13 is turned on (see FIG. 12D). Then, as shown by the arrow B in
FIG. 12D, the plunger 13a of the solenoid 13 is retracted. As a result,
as shown by the arrow C in FIG. 12D, the crank shaft 14 is allowed to be
rotated around the rotational center axis CL. Consequently, the output
part 14d of the crank shaft 14 pushes the abutment portion 3d of the
shade 3 to move and rotate the shade 3 around the shade rotational shaft
11 (located in through hole 3b) as shown by the arrow D in FIG. 12c (see
FIG. 5). As a result, the upper edge 3a of the shade 3 can be retracted
from the light path of light reflected from the reflector 2 to form the
high-beam light distribution pattern.

[0074]The solenoid 13 can be supported by the base member 12 such that the
moving direction of the plunger 13a of the solenoid 13 can be aligned
with the left-to-right direction of the projector type vehicle headlight
100 (in the perpendicular and normal to paper direction of FIG. 5 and in
the left-to-right direction in FIGS. 12B and 12D). Accordingly, when
compared to the case where the solenoid 13 is supported by the base
member 12 so that the moving direction of the plunger 13a of the solenoid
13 is aligned with the front-to-rear direction of the projector type
vehicle headlight 100 (in the left-to-right direction in FIG. 5), the
size in the front-to-rear direction of the projector type vehicle
headlight can be miniaturized.

[0075]In addition, in the projector type vehicle headlight 100 of the
first exemplary embodiment, the lens holder 15 for holding the projection
lens 4 can be formed of a member separate from the base member 12 as
shown in FIGS. 5, 7A, 7B, 10A, 10B, and 10C. In this instance, the lens
holder 15 can be made of a resin material while the base member 12 can be
made of a metal material. When compared with the case where the lens
holder 15 is made of a metal material, the projector type vehicle
headlight 100 can lighten as a whole.

[0076]In the projector type vehicle headlight 100 of the first exemplary
embodiment, as shown in FIG. 5, the lamp unit 50 can be allowed to be
rotated around the rotational shafts 12j and 12k extending in the
vertical direction of the projector type vehicle headlight 100. Then, as
shown in FIGS. 7A and 7B, the rotational shaft 12j and 12k and the base
member 12 are integrally formed with each other. Namely, the rotational
shafts 12j and 12k are made of a metal material integrally with the base
member 12.

[0077]Accordingly, when the rotational shafts 12j and 12k are made of a
resin material, they have an insufficient strength. However, the
projector type vehicle headlight 100 of the presently disclosed subject
matter can provide a sufficient strength to the rotational shaft, thereby
solving the problems associated with the conventional art.

[0078]In the projector type vehicle headlight 100 of the first exemplary
embodiment, as shown in FIG. 5, the rotational shafts 12j and 12k
extending in the vertical direction can be disposed on or near the
vertical line on which the center of gravity of the lamp unit 50 is
positioned. When the rotational shafts 12j and 12k are disposed away from
the vertical line containing the center of gravity of the lamp unit 50, a
predetermined moment can be applied to the rotational shafts, thereby
increasing the rotational resistance. However, the projector type vehicle
headlight 100 of the presently disclosed subject matter can further
reduce the rotational resistance of the lamp unit.

[0079]Furthermore, the shade 3 can be disposed just above the solenoid 13
as shown in FIG. 5. Accordingly, when compared to the case where the
solenoid 13 is disposed behind the shade 3 (at the right side of FIG. 5),
the projector type vehicle headlight 100 of the presently disclosed
subject matter can prevent the solenoid 13 from being heated by the light
source 1. Furthermore, when compared with the case where the solenoid 13
is disposed before the shade 3 (at the left side of FIG. 5), the distance
between the shade 3 and the projection lens 4 can be reduced.

[0080]The projector type vehicle headlight 100 of the first exemplary
embodiment can prevent temperature increase of the solenoid 13 due to the
heat from the light source 1 as well as reduce a distance between the
shade 3 and the projection lens 4.

[0081]Furthermore, in the projector type vehicle headlight 100 of the
first exemplary embodiment, the rotational center axis CL of the crank
shaft 14 extends in the vertical direction of the projector type vehicle
headlight 100 (in the up-to-down direction of FIGS. 9B and 9C). As shown
in FIG. 7A, the base member 12 can be formed with the grooves 12e and 12f
which can function as a bearing for rotatably supporting the crank shaft
14. The grooves 12e and 12f are disposed above and below the plunger 13a
of the solenoid 13 (see FIGS. 7A and 8B).

[0082]Accordingly, when compared with the case where a bearing for
rotatably supporting the crank shaft 14 is provided either above or below
the plunger 13a of the solenoid, the projector type vehicle headlight 100
of the first exemplary embodiment can suppress the axial deviation of the
crank shaft 14 so that the crank shaft 14 can smoothly rotate.

[0083]As shown in FIGS. 12B and 12D, when the solenoid 13 is turned on or
off, the plunger 13a of the solenoid 13 can move in the left-to-right
direction of the projector type vehicle headlight 100 (in the
left-to-right direction in FIGS. 12B and 12D). In this case, the
rotational center axis CL of the crank shaft 14 extends in the vertical
direction of the projector type vehicle headlight 100 (in the
perpendicular and normal to paper direction for FIGS. 12B and 12D), and
the plunger 13a of the solenoid 13 can linearly move. Then, the
trajectory of the contact point between the crank shaft 14 and the
plunger 13a of the solenoid 13 becomes an approximately arc around the
rotational center axis CL as a center.

[0084]If a crank shaft is fit into a cylindrical hole of a plunger that
linearly moves in a projector type vehicle headlight as shown in FIG. 2
(corresponding to FIG. 4 of Japanese Patent Application Laid-Open No.
2007-213938), the contact point between the crank shaft and the plunger
of the solenoid cannot move on an arc, meaning that the crank shaft
cannot smoothly move.

[0085]In view of this, as shown in FIGS. 12B and 12D the plunger 13a of
the solenoid 13 of the projector type vehicle headlight 100 of the first
exemplary embodiment has a groove 13a1 opened toward one direction, in
particular, rearward (lower side in FIGS. 12B and 12D). The crank shaft
14 can be fit in the groove 13a1 of the plunger 13a of the solenoid 13.

[0086]In this state, as shown in FIGS. 12B and 12D the solenoid 13 is
turned on or off to move the plunger 13a of the solenoid 13 in the
left-to-right direction of the projector type vehicle headlight 100 (in
the left-to-right direction in FIGS. 12B and 12D). The input part 14c of
the crank shaft 14 can be fit into the groove 13a1 of the plunger 13a of
the solenoid 13 so that it relatively moves within the groove 13a1 in the
front-to-rear direction of the projector type vehicle headlight 100 with
respect to the plunger 13a (in the vertical direction in FIGS. 12B and
12D).

[0087]As a result, the contact point between the crank shaft 14 and the
plunger 13a of the solenoid 13 can move on the approximate arc so that
the crank shaft 14 can smoothly rotate.

[0088]When the solenoid 13 is turned on or off and the crank shaft 14 is
made to rotate, the trajectory of the contact point between the crank
shaft 14 and the shade 3 can be an approximate arc when viewed from above
(plan view) and from its side (side view).

[0089]If a crank shaft is fit into a groove of a shade in a projector type
vehicle headlight as shown in FIG. 2 (corresponding to FIG. 4 of Japanese
Patent Application Laid-Open No. 2007-213938), the contact point between
the crank shaft and the shade cannot move on an arc, meaning that the
crank shaft and the shade cannot smoothly rotate.

[0090]In view of this, the shade 3 of the projector type vehicle headlight
100 of the first exemplary embodiment can include an abutment portion 3d
configured such that the output part 14d of the crank shaft 14 can abut
against the abutment portion 3d (see FIGS. 12A, 12B, 12C, and 12D), and
the abutment portion 3d can be formed by a half of an approximate
cylindrical surface extending in the left-to-right direction of the
projector type vehicle headlight 100 (in the perpendicular and normal to
paper direction in FIGS. 6B and 6C).

[0091]In this state, in the projector type vehicle headlight 100 of the
first exemplary embodiment, when the solenoid 13 is turned on or off to
rotate the crank shaft 14 as shown in FIGS. 12A and 12C. Then, the output
part 14d of the crank shaft 14 can move on the half cylindrical surface
of the abutment portion 3d of the shade 3.

[0092]As a result, the contact point between the output part 14d of the
crank shaft 14 and the abutment portion 3d of the shade 3 can move on the
approximate arc trajectory as seen in a plan view in the projector type
vehicle headlight 100 of the first exemplary embodiment. Furthermore, the
contact point between the output part 14d of the crank shaft 14 and the
abutment portion 3d of the shade 3 can move on the approximate arc
trajectory as seen in a side view so that the crank shaft 14 and the
shade 3 can smoothly rotate.

[0093]FIG. 13 is a schematic diagram illustrating a molding device 200
used for molding the base member 12 of the projector type vehicle
headlight of the first exemplary embodiment. As shown in FIG. 13, the
molding device 200 can include a fixed mold 201 (a first mold) and a
movable mold 202 (a second mold) relatively moved in the front-to-rear
direction of the projector type vehicle headlight 100 (in the
left-to-right direction of FIG. 13). Further included are slide molds 203
and 204 (first and second slide molds) moving upward and downward with
respect to the projector type vehicle headlight 100, respectively (upward
and downward in FIG. 13).

[0094]In particular, as shown in FIG. 13, the slide mold 203 can be
provided with a cavity 203a for the rotational shaft so that the
rotational shaft 12j extending upward in the projector type vehicle
headlight 100 (upper side in FIG. 13) can be integrally molded with the
base member 12. In addition to this, the slide mold 204 can be provided
with a cavity 204a for the rotational shaft so that the rotational shaft
12k extending upward in the projector type vehicle headlight 100 (upper
side in FIG. 13) can be integrally molded with the base member 12.

[0095]FIG. 14 is a schematic cross-sectional view illustrating a projector
type vehicle headlight 100 of a second exemplary embodiment made in
accordance with principles of the presently disclosed subject matter when
viewed from its right side. In the projector type vehicle headlight 100
of the first exemplary embodiment shown in FIG. 5, the base member 12 and
the housing 101 are connected with each other via the rotational shafts
12j and 12k of the base member 12, the bracket 52, the aiming screw 104
and the ball joint 105. In the projector type vehicle headlight 100 of
the second exemplary embodiment shown in FIG. 14, the base member 12 and
the housing 101 are connected with each other via an aiming screw 104 and
a ball joint 105.

[0096]Namely, the projector type vehicle headlight 100 of the second
exemplary embodiment, as shown in FIG. 14, does not include the bracket
52 (see FIG. 5) and the base member 12 does not include the rotational
shafts 12j and 12k (see FIG. 5).

[0097]FIG. 15 is a schematic view illustrating a molding device 200 for
molding the base member 12 of the projector type vehicle headlight 100
according to the second exemplary embodiment. As shown in FIGS. 13 and
15, the molding device 200 (see FIG. 15) can include partly the same
molds as those of the molding device 200 (see FIG. 13) for molding the
base member 12 of the first exemplary embodiment.

[0098]Specifically, when the base member 12 of the projector type vehicle
headlight 100 according to the first exemplary embodiment is molded, the
slide molds 203 and 204 having respective cavities 203a and 204a for the
rotational shafts are used as shown in FIG. 13. On the contrary, when the
base member 12 of the projector type vehicle headlight 100 according to
the second exemplary embodiment is molded, as shown in FIG. 15, the slide
molds 203' and 204' having no cavity for the rotational shafts are used.

[0099]In other words, the molds 201 and 202 are common to the cases of
molding the base member 12 of the first and second exemplary embodiments
(see FIGS. 13 and 15).

[0100]FIG. 16 is a schematic view illustrating a molding device 200 for
molding the base member 12 of the projector type vehicle headlight 100
according to a third exemplary embodiment. As shown in FIGS. 13 and 16,
the molding device 200 (see FIG. 16) can include partly the same molds as
those of the molding device 200 (see FIG. 13) for molding the base member
12 of the first exemplary embodiment.

[0101]In the projector type vehicle headlight 100 of the first exemplary
embodiment, as shown in FIG. 5, the center of gravity of the lamp unit 50
can be disposed on the front half part (left side in FIG. 5) of the base
member 12. In order to mold the base member 12 with the rotational shaft,
as shown in FIG. 13, the slide molds 203 and 204 can have the cavities
203a and 204a for the rotational shaft in respective front half parts
thereof (left side in FIG. 13), respectively.

[0102]On the other hand, in the projector type vehicle headlight 100 of
the third exemplary embodiment, the center of gravity of the lamp unit 50
can be disposed on the rear half part of the base member 12 as shown in
FIG. 16. Accordingly, the slide molds 203'' and 204'' can have the
cavities 203a'' and 204a'' for the rotational shaft in respective rear
half parts thereof (left side in FIG. 16), respectively.

[0103]In other words, the molds 201 and 202 are common to the cases of
molding the base member 12 of the first and third exemplary embodiments
(see FIGS. 13 and 16).

[0104]Accordingly, as in the first, second and third exemplary
embodiments, even when the positions of the rotational shafts 12j and 12k
are altered in accordance with the change of the specification of the
projector type vehicle headlight 100, there may be no need to change the
molds 201 and 202 of the molding device 200 so that they are common to
the various modifications.

[0105]Furthermore, in accordance with the change of the specification of
the projector type vehicle headlight 100, the light source 1, an ignitor
connected to the light source 1 (not shown), the reflector 2, and/or the
projection lens 4 may be changed. When doing so, the center of gravity of
the lamp unit 50 may also be changed. Even in this case, the common molds
201 and 202 can be used for molding rotational shafts 12j and 12k of the
base member 12 that have been shifted in position.

[0106]It should be noted that various exemplary embodiments can be
combined with one another, which fall within the scope of the presently
disclosed subject matter.

[0107]It will be apparent to those skilled in the art that various
modifications and variations can be made in the presently disclosed
subject matter without departing from the spirit or scope of the
presently disclosed subject matter. Thus, it is intended that the
presently disclosed subject matter cover the modifications and variations
of the presently disclosed subject matter provided they come within the
scope of the appended claims and their equivalents. All related and
conventional art references described above are hereby incorporated in
their entirety by reference.